Conductive composite and method for manufacturing a conductive composite

Abstract

A conductive composite includes a first layer of elastomeric polymer, a layer of conductive fluorofluid on the first layer of elastomeric polymer, and a second layer of elastomeric polymer on the layer of conductive fluorofluid.

What is claimed is: 
     
       1. A conductive composite comprising:
 a first layer of elastomeric polymer; 
 a layer of composite fluid on the first layer of elastomeric polymer, wherein the composite fluid comprises a fluorofluid that is not cured or hardened into a solid state and a solid conductive additive; and 
 a second layer of elastomeric polymer on the layer of conductive fluorofluid, 
 wherein edges of the conductive composite are sealed around the layer of conductive fluorofluid. 
 
     
     
       2. The conductive composite of  claim 1  wherein the fluorofluid includes at least one of a perfluoropolyether, a fluorinated acrylate oligomer, and combinations thereof. 
     
     
       3. The conductive composite of  claim 1  wherein the fluorofluid has a viscosity in a range of from about 2,000 cP to about 10,000,000 cP. 
     
     
       4. The conductive composite of  claim 1  wherein the solid conductive additive includes at least one of carbon fiber, coated carbon fiber, and a metallic material. 
     
     
       5. The conductive composite of  claim 1  wherein the solid conductive additive includes a metallic material, wherein the metallic material includes at least one of stainless steel, brass, iron, nickel, titanium, aluminum, copper, silver, gold, platinum, palladium, and zinc. 
     
     
       6. The conductive composite of  claim 1  wherein the layer of composite fluid further comprises a compatibilizing agent. 
     
     
       7. The conductive composite of  claim 1  wherein the layer of composite fluid further comprises an organic compatibilizing agent, and wherein the organic compatibilizing agent comprises at least one of an ionic surfactant, a nonionic surfactant, and combinations thereof. 
     
     
       8. The conductive composite of  claim 1  wherein the layer of composite fluid further comprises an additive to increase thermo-oxidative stability, wherein the additive comprises at least one of a phosphate, an iron oxide, a phenolic, an antioxidant, a metal passivator, and combinations thereof. 
     
     
       9. The conductive composite of  claim 1  wherein the first layer of elastomeric polymer comprises at least one of siloxane, fluorosiloxane, perfluoropolyether, polybutadiene, polyester, polycarbonate, polyurethane, polyurea, polyurethane-urea, epoxy, acrylate, natural rubber, butyl rubber, polyacrylonitriles, ethylene propylene diene monomer (EPDM) rubber, and combinations thereof. 
     
     
       10. The conductive composite of  claim 1  wherein the second layer of elastomeric polymer comprises at least one of siloxane, fluorosiloxane, perfluoropolyether, polybutadiene, polyester, polycarbonate, polyurethane, polyurea, polyurethane-urea, epoxy, acrylate, natural rubber, butyl rubber, polyacrylonitriles, ethylene propylene diene monomer (EPDM) rubber, and combinations thereof. 
     
     
       11. The conductive composite of  claim 1  wherein a thickness of the first layer of elastomeric polymer is within a range of from about 0.01 mm to about 100 mm. 
     
     
       12. The conductive composite of  claim 1  wherein a thickness of the second layer of elastomeric polymer is within a range of from about 0.01 mm to about 100 mm. 
     
     
       13. The conductive composite of  claim 1  wherein a thickness of the layer of composite fluid is less than or equal to at least one of a thickness of first layer of elastomeric polymer and a thickness of the second layer of elastomeric polymer. 
     
     
       14. The conductive composite of  claim 1  wherein a thickness of the layer of composite fluid is greater than at least one of a thickness of first layer of elastomeric polymer and a thickness of the second layer of elastomeric polymer. 
     
     
       15. The conductive composite of  claim 1  wherein a thickness of the layer of composite fluid is greater than a total of a thickness of first layer of elastomeric polymer and a thickness of the second layer of elastomeric polymer. 
     
     
       16. The conductive composite of  claim 1  further comprising a reinforcement mesh in contact with the layer of composite fluid. 
     
     
       17. The conductive composite of  claim 16  wherein the reinforcement mesh comprises a fabric. 
     
     
       18. The conductive composite of  claim 1  the conductive composite comprises an edge length of elastomeric polymer around the layer of composite fluid sealing the composite fluid within the conductive composite. 
     
     
       19. The conductive composite of  claim 18  wherein the edge length is greater than or equal to at least one of a thickness of the first layer of elastomeric polymer and a thickness of the second layer of elastomeric polymer. 
     
     
       20. The conductive composite of  claim 1  wherein the second layer of elastomeric polymer is bonded to the first layer of elastomeric polymer. 
     
     
       21. The conductive composite of  claim 1  wherein the conductive composite exhibits a minimum sheet resistance of less than about 100 Ohm/sq. 
     
     
       22. The conductive composite of  claim 1  wherein the conductive composite exhibits an elongation at break of greater than or equal to about 10%. 
     
     
       23. The conductive composite of  claim 1  wherein the conductive composite exhibits a tensile strength greater than or equal to about 3 MPa. 
     
     
       24. The conductive composite of  claim 1  wherein the conductive composite has a density of less than about 7 g/mL. 
     
     
       25. The conductive composite of  claim 1  wherein the conductive fluorofluid has a loss modulus greater than a storage modulus. 
     
     
       26. The conductive composite of  claim 1  wherein the conductive composite is a portion of an aircraft. 
     
     
       27. The conductive composite of  claim 1  wherein the conductive additive has an aspect ratio of less than about 2. 
     
     
       28. A method for manufacturing a conductive composite, the method comprising:
 forming a first layer of elastomeric polymer; 
 forming a layer of composite fluid on the first layer of elastomeric polymer, wherein the composite fluid comprises a fluorofluid that is not cured or hardened into a solid state and a solid conductive additive; and 
 forming a second layer of elastomeric polymer on the layer of conductive fluorofluid, 
 wherein edges of the conductive composite are sealed around the layer of conductive fluorofluid.